Continuous high temperature electrothermal furnace



G. c. cox 2,068;447

CONTINUOUS HIGH TEMPERATURE ELECTROTHERMAL FURNACE Jan. 19, 1937.

Filed March 50, 1953 3 Sheets-Sheet l C eo/ye 6. 60.2:

m, M mm G. C. COX

Jan. 19, 1937.

CONTINUOUS HIGH TEMPERATURE ELECTROTHERMAL FURNACE 1955 3 Sheets-Sheet 2 Filed March 50 Jan. 19, 1937. G. c. cox 2,068,447

CONTINUOUS HIGH TEMPERATURE ELECTROTHERMAL FURNACE Filed March 50, 1933 3 Sheets-Sheet 3 Gearye 6.

We; I

Patented Jan. 19, 1937 UNITED STATES com'muous men mmm'runn ELEC- zrao'rnnnmr. FURNACE George Chandler Cox, Modesto, Calif. Application March 80, 1933, Serial No. 883,603

5 Claims.

This invention relates to improve ents in continuous high temperature 'electrormal processes involving physical reactions, chemical reactions or combinations of physical and chemical reactions.

An object of this invention is the provision of a continuous process for efiecting high tempera! ture physical reactions more efflciently and economically and under more uniform conditions than is known to the present art. Such reactions are: complete or fractional distillations or sublimations above or below atmospheric pressure; crystallizations; recrystallizations; and changes from an amorphous to a crystalline state or' from a crystalline to an amorphous state.

Another object of this invention is the provision of a continuous process for effecting high temperature chemical reactions under more efficient economic and uniform conditions than is known to the present art. Such high temperature chemical reactions are: reactions between two or more solids; reactions between one or more solids and one or more liquids at the reacting temperature; reactions between one or more solids and one or more gases at the reacting temperature; reactions between one or more solids, liquids or gases; and high temperature catalytic reactions.

A further object of this invention .is the provision of a continuous process for effecting a high temperature chemical reaction as set forth, the product or products of which are subjected to a physical reaction as set forth, all within one reacting chamber.

A further object of this invention is the provision of a continuous process for reacting a solid, liquid or gas corrosive to a refractory lining or metal casing at the reacting elevated temperature without damage to such lining or casing. I

By a continuous process is meant one in which there is no cooling down or stopping of the operation, the electric energy being continuously supplied. In general, the charged materials are continuously supplied and the products are continuously discharged, although the charging and discharging may be intermittent.

Fig. 1 is a vertical cross section of one type of furnace having the screw conveyor for carrying off the reacted material.

Fig. 2 is a view similar to Figure 1 showing a different means of removing the reacted material, the heating means being omitted.

Fig. 3 is a vertical section illustrating one method of introducing liquids into the furnace.

Fig. 4 illustrates one way of cooling the upper various positions of the electrodes and various wiring diagrams. V Fig. 6a is a view illustrating a wiring for induction heating.

Figs. 1, 2, 3 and 4 are vertical schematic sectional views of various modified forms in which various means are illustrated for discharging solids and for charging and discharging liquids and gases;

. Fig. ;5 is a vertical schematic section of an apparatus for the processing of pressed forms.

Figs. 6 to 6' inclusive, are schematic diagrams illustrating the supplying of single and polyphase electric currents.

In the drawings similar numbers refer to similar parts.

Fig. 1 shows a vertical section of one form of device in which the high temperature continuous processes are conducted. The horizontal crosssection may be circular or rectangular as desired. In this section, I represents a highly'refractory lining, which may be made from the charge itself, backed up by other refractory and thermal insulating materials 2 and 3. Thme refractories are contained within the gas tight casing 4. .The

bottom of the casing. contains a porous refractory 6 through which the discharge gases or liquids pass to the exhaust pipe I. Hopper 8 contains the solid or solids to be charged .into the furnace by means of the screw charging device 9, or other customary charging device, such as a piston type charging ram.

A charging device is required which will produce a high pressure capable of forcing the charge upward into the center of the controlled temperature reaction zone l0. Heat energy may be supplied through electrodes 5 which may be two or more in number according to whether single or polyphase electric energy is used. The arrangement for supplying electrical energy to the reaction zone Hi may also be accomplished by any of the well known methods, such as direct or indirect resistance, direct or indirect arc,.or induce tion heating, or by combinations of more than one of these methods. The charging device 9 must also be capable of forcing the solid reaction products upward to the screw conveyor H by continually forcing the fresh charge into the reacting zone in. The solid reaction products are gnoved by screw conveyor ll into bell hopper i2. Any

suitable form of mechanical conveyor may be used instead. of screw conveyor II. The solid reaction products are finally discharged from hell hopper'il through bell hopper It by means I of the cone bell valves i4 and ii. In such reactions where it is desired to discharge the gaseous products of reaction in a countercurrent flow to the solid products of reaction, pipe I. may be closed and the gases passed through porous filter I and discharged at 1. Where a concurrent fiow of solid and gaseous product is desired, pipe I may be closed and the gases discharged through pipe II. It is obvious that any liquid reaction products could be discharged at pipe I. It is often desirable to make the refractory linings i, 2 and I and filter 6 from the same material as the most refractory solid component of the charge.

It will be noted that the angle a which the side walls make with each other will vary considerably. in If the charge and solid products remain powdery or granular the angle a may be made small. However, if the reacting zone tends to clog due to sintel'ing. crystallization or packing, the angle a must be increased until the upward force on the charge is sufllcient to break the bridge of material away from the walls. The practical maximum limit of angle a is obviously 180.

Fig. 2 shows a vertical section of a discharge arrangement which may be used when the discharge a material tends to be lumpy due to crystallization,

recrystallization, sintering or partial fusion. Revolving hammers l1 may be used to pulverize the material so that the conveyors II will discharge the material into the bell hoppers.

Fig. 3 shows an arrangement in which it is desired to obtain a countercurrent reaction between one or more solids and a liquid which may be introduced through pipe It. To prevent the eacapeofgaseaatrapmaybeusedon pipe ll,as shown. The inner end of pipe it may be made to extend into the reaction zone by the use of a watercooled Jacket.

Fig. 4 shows an arrangement in which it is desired to cool the solid reaction products before discharging them from the furnace atmosphere. The solid reaction products can be made to pass up through and over the water cooled Jacket ll. The shape of the water cooled jacket is can be varied as desired.

Pig: 5 shows a schematic sectional view of a reaction chamber in which it is desired to treat pressed shapes such as brick, electrodes, or other similar shapes. The process for treating brick or other pressed shapes with the particular schematic arrangement shown is somewhat as follows: The brick are forced upward by plunger II. When plunger is has reached the upper end of its stroke, plunger III forces a brick partway under the brick that plunger II has forced up. Plunger II can then be lowered to the bottom of its stroke so that plunger 20 can force the consecutive brick in alignment with the vertical column of brick. The operation is then repeated. In order to insure a uniform treatment, it is usually desirable to prevent the formation of vertical channels in the reaction zone. This vertical channeling may be prevented by introducing granular material of somewhat similar composi- 70 tion to the brick around the column of brick by means of the conventional screw charging device l, or by means of plungers in place of the screw charging device.

The brick or electrodes may be removed from 75 the discharge end of the reaction chamber by can? means of a chain drag 2i and be discharged from the gate hopper II through gate hopper it by means of the gates 24 and II. The gases of reaction may be discharged through the filter l and pipe I or, if desired, from the pipe I...

Long cylindrical electrodes or rods may be processed by modifying the charging and discharging mechanism to accommodate such shapes. In general, it is desirable that such cylinders have their axes perpendicular.

Various means of supplying electrical energy to the reaction zone are schematically shown in Fig. 6a. to Fig. 69. Single phase two electrode resistance or are heating is indicated in Fig. 6a in which the electrodes are in a horizontal plane. Polyphase multiple electrode resistance or arc heating is indicated in Fig. 6b in which the electrodes are in a horizontal plane. Single or polyphase heating is indicated in Fig. 8c in which the coacting electrodes are in a vertical plane. Axial flow of single phase heating current is indicated in Fig. 6d. Both axial and lateral heating currents are indicated in Fig. 6e supplied by polyphase current connections. Top electrode heating is indicated in Fig. 6!. Induction heating is indicated in Fig. 6a in which an induction coil 28 may be contained within the metallic case 4. For induction heating, the case must be made non-inductive and must not form a closed circuit around its circumference. It is understood that resistance, are or induction heating or combinations of two or more means with single or multiple electrodes may be used within the spirit of the appended claims.

Various examples will now be given in order to illustrate the various objects as defined:

(i) For the distillation of coal, the coal is forced upward by the device 9 into the electrically heated reaction zone. Coke is removed by the top discharge device and the distilled gases are preferably removed through pipe 1, but may be removed through pipe l6.

(2) For the calcination of carbon, a similar process is carried out and the volatilized gases are preferably removed through pipe I. In general, it is desirable to scrub the volatilized gases to remove all heavy hydrocarbons and to recirculate a part of such gases in a countercurrent direction to the carbon. The scrubbed gases would then be pumped into the reaction chamber through pipe It, and all gases would be removed through pipe 1.

(3) In a continuous process for the manufacture of graphite, the coke or coal would be forced upward by the mechanical device 8 and the gases of reaction and the sublimed products of reaction should be removed through the pipe I. By removing the gases in this manner. slight contamination of the graphite will result. The graphite is removed through the bell hoppers. In a continuous graphite process, it would be desirable to have the graphite pass upward through and then over a water cooling jacket it, as shown in Fig. 4. By such method the graphite would be cooled below its oxidation temperature before being discharged to the atmosphere. In a continuous process for the manufacture of graphite electrodes or other pressed forms, the raw electrodes would be forced upward through the center of the reaction zone; and raw granular or pulverized electrode material would be forced upward around the electrodes as shown in Fig. 5, so that no channeling or unequal heating would result.

tallization, the method used would be practically the same as that for the manufacture of graphite electrodes. a

'(5) An illustration of the continuous reaction of one or more solids with one or more liquids would be the continuous production of carbon di-' sulphide. In such a process the carbon would be fed in by the charging device 9, and liquid sulphur would be fed into the reaction zone in a countercurrent direction to that of the carbon by introducing it through the pipe [6 of Fig. 3.

The vapors of reaction would generally be discharged from the pipe 1. When it is desirable to introduce the sulphur in the solid, state with the carbon, the vaporsof reaction would not be withdrawn through the pipe I but through the pipe I B.

(6) An illustration of the continuous reaction and the spent ore is discharged from the top through the bell hopper dischargedeviceh A similar process would be required in the manufacture of ferric chloride in which iron oxide ore and carbon may be fed into the reaction zone in such proportions that the iron ore is ordinarily reduced to sponge iron, which is then converted to anhydrous ferric chloride by chlorine gas fed into the reaction zone though pipe IS. The anhydrouschloride would be removed through pipe I.

It is observed that one of the chief advantages f of carrying out high temperature reactions by the methods described when compared to the present art is that the outside casing may be a metallic gas tight casing remaining at or near atmospheric temperature. When a metallic casing is at an approximate atmospheric temperature, it is practically inert to gases such as chlorine, sulphur vapor and the like. Such vapors are highly corrosive to construction metals at elevated temperatures. I

Another distinct advantage in comparison to the present art. is that an upward pressure feed of the solid materials insures a uniform feeding of fresh charge into the reaction zone, a uniform passage of material through the reaction zone and a uniform discharge of material from the reaction zone. The inherent diilicultles of nonuniform feed and channeling observed in a down feed are not obtained in the process described. Where the charge acts as a resistance for the electric current, the heating is much more uniform in an up feed than in a down feed furnace, because the mechanical pressures exerted upon a given cross-section are more nearly equal- 3 charge falls in toward the center and the-charge cannot be made to'conveniently act as its own refractory.

Another distinct advantage of this "up feed reaction :hamber is that bridging and clogging can be eliminated. In a "down feed" furnace bridging and clogging is often a serious difllculty.

It is understood that the particular forms-of apparatus shown and described, and'the particular procedure set forth are presented for purposes of explanation and illustration, and that various modifications of said apparatus and procedure can be made without'departing from the invention as defined in the appended claims.

. Whatis claimed is:

1. An electric furnace comprising a chamber,

the chamber having a charging zone at its bottom, a reaction zone above the charging zone,

and a cooling zone above the reaction zone, means for electrically heating the reaction zone, and means for charging solid material including loose material into the bottom of the charging zone and upwardly to the reaction zone and for forcing the reacted solid material upwardly through the cooling zone, the solid material forming a thermal insulation during passage through the cooling zone, the chamber and charging means being so constructed as to cause the mass of moving solid material to increase in cross-section as it passes upwardly through the chamber.

2. An electric furnace comprising a chamber, the chamber having a charging zone at its bottom, a reaction zone above the charging zone, and a cooling zone above the reaction zone, means for electrically heating the reaction zone, and means for charging solid material including loose material into the bottom of the charging zone and upwardly to the reaction zone and for forcing the reacted solid material upwardly through the cooling zone, the solid material forming a refractory wall for the reaction zone and a thermal insulation above the reaction zone during passage through the chamber, the charging means having its outer edges inward of the sides of the chamber, thereby causing the mass of solid material to increase in cross-section as it passes upwardly through the chamber.

3. An electric furnace comprising a chamber, the chamber having a charging zone at its bottom, a reaction zone above the charging zone, and a cooling zone above the reaction zone, means for electrically heating the reaction zone, means for charging liquid material into the chamber, and means for charging solid material including loose, material into the bottom of the charging zone and upwardly to the reaction zone and for forcing the reacted solid material upwardly through the cooling zone, the solid material forming a thermal insulation during passage through the cooling zone, the chamber and charging means being so constructed as to cause the mass of moving solid material to increase in cross-section as it passes upwardly through the chamber.

4. An electric furnace comprising a chamber, the chamber having a charging zone at its bottom, a reaction zone above the charging zone, and a cooling zone above the reaction zone, means for electrically heating the reaction zone, means for charging gaseous material into the chamber, and means for charging solid material including loose material into the bottom of the charging zone and upwardly to the reaction zone and for forcing the reacted solid material up- Iardly through the cooling sone, the solid material ionning a thermal insulation during passage through the cooling "zone, the chamber and charging means being so constructed as to cause the mass of moving solid material to increase in cross-section as it passes upwardly through the chamber. I

'5. An electric iurnace comprising a chamber, the chamber having a charging zone at its bottom, a reaction zone above the charging zone, and a cooling zone above-the reaction none, means torelectrically heating the reaction none, means for charting liquid and gaseous material into the chamber, and means iorcharging solid material including loose material intothe bottom of the charging cone and upwardly to the reaction zone and for forcing the reacted solid material upwardly through the cooling none, the solid material iormlng a thermal insulation during passage through the cooling' zone, the chamber and charging means being so constructed as tocause the mass of moving solid material to increase in cross-section as it passes upwardly through the i0 

